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CARNEGIE STEEL COMPANY 



GENERAL STATISTICS 

AND 

SPECIAL TREATISE 

ON 

HOMESTEAD STEEL WORKS 



PITTSBURGH, PENNSYLVANIA 



CHARLES N. BOYD, 

431 WOOD STREET, 

PITTSBURSH, PA. 



First Edition, May, 1912 









Copyright, 1912 

CARNEGIE STEEL COMPANY 

Pittsburgh, Pa. 



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CARNEGIE STEEL' COMPANY 

GENERAL STATISTICS 

Acreage covered by manufacturing properties and accessories 2,358 

Number of employes 37,000 

Average monthly pay roll $2,275,000 

Gross tons of ore consumed per 24 hour day 40,000 

Gross tons of coke consumed per 24 hour day 19,500 

Gross tons of coal consumed per 24 hour day 8,000 

Gross tons of limestone consumed per 24 hour day 10,000 

Cubic feet of natural gas consumed per 24 hour day 106,000,000 

Miles of Standard Gauge Railroad Track 260 

Steam horse power produced per 24 hour day 7,250,000 

Electric horse power produced per 24 hour day 850,000 

Total production in gross tons for 24 hour day 95,000 

Gross tons of finished materials produced per 24 hour day 20,000 

Gross tons of shipping capacity per 24 hour day 22,000 



CARNEGIE 

STEEL 

COMPANY 



CARNEGIE 

STEEL 

COMPANY 



CARNEGIE STEEL COMPANY 

THEORETICAL CAPACITY IN GROSS TONS PER YEAR OF VARIOUS PRODUCTS 

Blast Furnaces: 

Pig Iron 8,381,000 

Spiegeleisen, Ferromanganese, etc 108,000 

Bessemer Ingots 3,930,000 

Basic Open Hearth Ingots 5,058,000 

Blooms, Billets and Slabs X 6,980,000 

Flue Dust Briquettes ' 120,000 

By-Product Coke . .' . 500,000 

X Tonnage of Blooms, Billets and Slabs is rolled in the various finishing mills to produce 
6,760,000 G. T. of finished material. 



CARNEGIE STEEL COMPANY 

THEORETICAL CAPACITY IN GROSS TONS PER YEAR OF FINISHED MATERIAL 

Sheet and Tin Bars 1,640,000 

Universal and Sheared Plates 1,220,000 

Beams, Channels, Angles, etc 874,000 

Rails 868,000 

Axles 180,000 

Steel Ties 43,000 

Steel Mine Timbers 1,000 

Steel Sheet Piling 15,000 

Splice Bars 104,000 

Slack Barrel and Keg Hoops 18,000 

Steel Wheels ' 112,500 

Twisted Bars 45,000 

Merchant Bars, Hoops, Cotton Ties, etc 1,450,000 

Tapered Spring Steel 3,000 

Ingot Moulds, Stools, Castings and Rolls 175,000 

Armor Plate 12,000 

Total 6,760,500 



CARNEGIE 

STEEL 

COMPANY 



CARNEGIE 

STEEL 

COMPANY 



CARNEGIE STEEL COMPANY 

PLANTS 

Duquesne Steel Works and Furnaces, South Duquesne, Pa. 

Edgar Thomson Steel Works and Furnaces, Bessemer, Pa. 

Homestead Steel Works, Munhall, Pa. 

Carrie Furnaces, Rankin, Pa. 

Edith Furnaces, Pittsburgh, Pa. 

Isabella Furnaces, Etna, Pa. 

Lucy Furnaces, Pittsburgh, Pa. 

Neville Furnace, Neville Island, Pa. 

Clark Mills, Pittsburgh, Pa. 

McCutcheon Mills, Pittsburgh, Pa. 

Painter Mills, Pittsburgh, Pa. 

Lower Union Mills, Pittsburgh, Pa. 

Upper Union Mills, Pittsburgh, Pa. 

Howard Axle Works, Homestead, Pa. 

Schoen Steel Wheel Works, McKees Rocks, Pa. 

Bellaire Steel Works and Furnaces, Bellaire, 0. 

Clairton Steel Works and Furnaces, Clairton, Pa. 



CARNEGIE 

STEEL 

COMPANY 



CARNEGIE STEEL COMPANY 
PLANTS— Continued 



Columbus Steel Works and Furnaces, Columbus, O. 

Mingo Steel Works and Furnaces, Mingo Junction, O. 

New Castle Steel Works and Furnaces, New Castle, Pa. 

Ohio Steel Works and Furnaces, Youngstown, O. 

Sharon Steel Works and Furnace, Sharon, Pa. 

South Sharon Steel Works and Furnaces, South Sharon, Pa. 

Greenville Mills, Greenville, Pa. 

Monessen Mills, Monessen, Pa. 

Lower Union Mills, Youngstown, O. 

Upper Union Mills, Youngstown, O. 

Niles Furnace, Niles, O. 

Steubenville Furnace, Steubenville, O. 

Zanesville Furnace, Zanesville, 0. 

Waverly Warehouses, Newark, N. J. 

Pittsburgh Warehouse, Pittsburgh, Pa. 

Cleveland Warehouse, Cleveland, O. 

Baltimore Warehouse, Baltimore, Md. 



CARNEGIE 

STEEL 

COMPANY 



PRODUCTS 



Pig Iron and Furnace Products 

Ferromanganese and Spiegeleisen 

Open Hearth and Bessemer Steel, Alloy Steels 

Ingots, Billets, Blooms, Slabs and Sheet Bars 

Armor and Vault Plate 

Plates for Bridges, Ships, Tanks, Boilers and Cars 

Rolled Structural Shapes 

Beams, Channels, Angles, Tees and Zees 

Steel Mine Timbers and Steel Sheet Piling 

Bar Mill Products 

Concrete Reinforcement Bars, Agricultural Shapes 

Miscellaneous and Special Shapes 

Merchant Bars 



CARNEGIE 

STEEL 

COMPANY 



PRODUCTS 



Squares, Rounds, Half Rounds, Hexagons, Ovals, Half Ovals 

Flats, Skelp, Bands, Hoops, Cotton Ties 

Hoops for Slack Barrel Cooperage 

Tire and Vehicle Spring Steel 

Rails, Track Material 

Rails and Splice Bars, Duquesne Rail Joints 

Track Accessories 

Steel Cross Ties 

Forgings 

Axles and Wheels 

Connecting Rods, Crank Shafts and Arch Bars 

Oil Derricks and Drilling Rigs 

Steel Gear Blanks and Industrial Wheels 



CARNEGIE STEEL COMPANY 

GENERAL OFFICES 
Pittsburgh, Carnegie Building 



DISTRICT OFFICES 



Birmingham, Brown-Marx Building 

Boston, 120 Franklin Street 

Buffalo, EUicott Square Building 

Chicago, Commerical National Bank Building 

Cincinnati, Union Trust Building 

Cleveland, Rockefeller Building 

Denver, First National Bank Building 



Detroit, Ford Building 

New Orleans, Maison Blanche 

New York, Hudson Terminal 

Philadelphia, Pennsylvania Building 

Pittsburgh, Carnegie Building 

St. Louis, Third National Bank Building 

St. Paul, Pioneer Building 



PACIFIC COAST REPRESENTATIVES 
United States Steel Products Company, Pacific Coast Department 
Los Angeles, Jackson Street and Central Avenue San Francisco, Rialto Building 

Portland, Selling Building Seattle, 4th Avenue South and Connecticut Avenue 

EXPORT REPRESENTATIVES 

UNITED STATES STEEL PRODUCTS COMPANY 

GENERAL OFFICES 
New York, Hudson Terminal 



Antwerp 

Batavia 

Bombay 

Brussels 
Buenos Aires 
Capetown 



DISTRICT OFFICES 

Johannesburg 

Lima 

London 

Mexico City 

Montreal 

Rio de Janeiro 



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Shanghai 

Sydney 

Toronto 

Valparaiso 

Vancouver 

Winnipeg 



CARNEGIE STEEL COMPANY 

HOMESTEAD STEEL WORKS 

MUNHALL, PENNSYLVANIA 




Office 



All "Visiting Passes" for Homestead Steel Works are issued at General Offices of the Carnegie Steel Company, 

1116 Carnegie Building, Pittsburgh, Pa. 



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GENERAL VIEW OF HOMESTEAD STEEL WORKS 



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Gbnbhal View of Homestead Steel Wo 



HOMESTEAD 

STEEL 

WORKS 



The Homestead Steel Works is situated on the south bank of the Monongahela River at 
Munhall, Pennsylvania, eight miles from Pittsburgh. 

The original plant was built by the Pittsburgh Bessemer Steel Company in 1880-81 and 
operated by them until its sale, in 1883, to Carnegie, Phipps & Company, when the plant was rebuilt 
and enlarged. 

On July 1, 1892, the Carnegie Steel Company, Limited, took possession, and eight years later 
the present name of the Company was adopted. 

Additional departments have been added from time to time by the Carnegie Steel Company 
until it is now the largest steel works in the United States. 

The plant covers 123.8 acres. 



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CARNEGIE 

STEEL 

COMPANY 



STATISTICS OF OPERATION 

(Including Carrie Furnaces, Howard Axle Works and Schoen Steel Wheel Works) 

Number of employees 10,000 

Number of cars handled per day 1,630 

Miles of car length 12 

Tons produced per day 23,192 

Tons produced per minute 16 

Tons produced per day per man 2.4 

Tons of finished product produced per day 5,750 

Tons Armor Department produces per day 30 

Tons of ore consumed per day 5,818 

Tons of coal consumed per day 2,014 

Cubic feet of natural gas consumed per day 62,471,934 

Miles of railroad track 120 

Length of stacks, in miles 6.92 

Acreage 279.5 

Acres under roof 59.7 

Steam horse power produced per day . 1,212,720 

Electric horse power produced per day 341,683 



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HOMESTEAD 

STEEL 

WORKS 



STATISTICS OF PRODUCTION 

The annual capacity, in gross tons, of Homestead Steel Works of finished and semi-finished 
products is about as follows: 

Pig iron 980,000 

Ingots 2,725,000 

Universal plates 338,000 

Sheared plates 550,000 

Beams, channels, angles, piling, etc 434,500 

Steel railroad ties 43,000 

Axles 180,000 

Steel wheels, Schoen and Slick 112,500 

Small angles, rounds, squares, flats, etc . . 34,000 

Armor plate 12,000 

Castings ■ . . . 4,500 



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CARNEGIE 

STEEL 

COMPANY 



THE BLAST FURNACE DEPARTMENT 

This department of the Homestead Steel Works is located across the Monongahela River and 
operated under the name of Carrie Furnaces. This department consists of seven modern furnaces 
with all the necessary equipment to make it one of the most up-to-date blast furnace plants in the 
world. The Furnace Department is connected with the main plant by a hot metal bridge, built 
especially for the purpose of carrying the molten pig iron direct to the open hearth steel making 
departments in the main plant. 

At this plant there are nine gas engines operated by the waste gas from the blast furnaces ; five 
of these engines and one steam turbine operate A. C. generators that produce electric power for the 
use of the Homestead Steel Works and the Universal Portland Cement Plant. 

There are also six steam engines driving D. C. generators. 

Total power generated — 15,200 K. W. 



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STEEL 

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STEEL 

COMPANY 




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STEEL 

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STEEL 

COMPANY 




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HOMESTEAD 

STEEL 

WORKS 



ELECTRIC POWER STATION 

The equipment of the Homestead Steel Works Power Station consists of: 

Three D. C. generators of 800 K. W. each, driven by three tandem compound engines 
27 & 46x42". 

Two D. C. generators of 375 K. W. each, driven by two simple 24x42" engines. 

Two D. C. generators of 150 K. W. each, driven by one simple engine 20x21" and one simple 
engine 19x20". 

Two 500 K. W. motor generators. These two generators are driven by A. C. power from 
Carrie Furnaces Power Plant or from the Duquesne Power Plant, both these power plants being 
connected with Homestead Steel Works. 

Seven arc machines, driven by a 20x36" simple engine. 

Two arc machines, driven by two 100 H. P. motors. 



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CARNEGIE 

STEEL 

COMPANY 



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THE OPEN HEARTH DEPARTMENT 



This department consists of the following: 

(Y 38-ton] 

No. 1 Open Hearth, 10 Furnaces^ 2 30-ton f Natural Gas. 

[l 25-tonJ 



No. 2 Open Hearth, 17 Furnaces< 



'8 38-tonl 

4 50-ton f Natural Gas. 

4 40-tonJ 

1 15-ton, Electricity or Gas. 



No. 3 Open Hearth, 24 Furnaces, all 50-ton, Natural Gas. 



No. 4 Open Hearth, 14 Furnaces<! . __ : >Natural Gas. 

4 75-ton 



Total, 65 Furnaces, 50 tons per heat average capacity. 



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STEEL 

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STEEL 

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STEEL 

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THE BESSEMER DEPARTMENT 

This department consists of the following: 

5 Iron cupolas, 10 feet in diameter by 30 feet in height. 
2 Converting vessels, nominal capacity 10 tons each. 



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STEEL 

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STEEL 

COMPANY 



BLOOMING AND SLABBING MILLS 

28" and 38" Blooming Mills roll blooms 4x4" or over. These mills are served by four soaking 
pits of three holes and four of four holes respectively and are driven by a 28x48" and a 50x72" 
reversing engines respectively. 

40" Blooming Mill rolls blooms for the 35" Structural Mill. It is served by four soaking pits of 
five holes each, two ingots per hole, and driven by a 55x60" reversing engine. 

33" Blooming Mill rolls blooms for the 23" and 33" Structural Mills. It is served by two soaking 
pits of five holes each, four ingots per hole, and is driven by a 46x60" simple engine. 

32" Slabbing Mill rolls slabs for the 140", 84" and 72" Sheared Plate Mills. It is served by six 
soaking pits, one of three, one of four, and four of five holes each, two ingots per hole, and is driven 
by one 30x54" and one 40x54" reversing engine. 

30" Slabbing Mill rolls slabs for the 128" Sheared Plate Mill and the 42" Universal Plate Mill. 
It is served by six soaking pits of four holes each, two ingots per hole and is driven by one 46x60" 
and one 28x48" reversing engine. 



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STEEL 

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CARNEQIE 

STEEL 

COMPANY 




38" Blooming Mill 



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STEEL 

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STEEL 

COMPANY 



STRUCTURAL MILLS 

35" Structural Mill rolls 12" to 27" beams, channels and angles from blooms furnished by the 
40" Blooming Mill, has one reheating furnace for emergencies, but rolls most blooms direct. It is 
driven by a tandem compound 52 & 78x60" engine. 

33" Structural Mill rolls beams, channels and angles from blooms furnished by the 33" Blooming 
Mill, has two heating furnaces and is driven by a 54x66" simple engine. 

23" Structural Mill rolls beams, channels and angles from blooms furnished by the 33" Bloom- 
ing Mill, has three heating furnaces and is driven by a 42x48" simple engine. 



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STEEL 

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STEEL 

COMPANY 




35" Beam Yard 



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STEEL 

WORKS 



SHEARED PLATE MILLS 

140" Sheared Plate Mill rolls plates from slabs furnished by the 32" Slabbing Mill. It is 
served by six heating furnaces and is driven by a 42 & 56x60" tandem compound engine. 

128" Sheared Plate Mill rolls plates from slabs furnished by the 30" Slabbing Mill. It is 
served by nine heating furnaces, which also serve the 42" Universal Plate Mill, and is driven by a 
46x60" simple engine. 

84" Sheared Plate Mill rolls plates from slabs furnished by the 32" Slabbing Mill. It is served 
by six heating furnaces and is driven by a 34 & 54x60" tandem compound engine. 

72" Sheared Plate Mill rolls plates from slabs furnished by the 32" Slabbing Mill. It is served 
by four heating furnaces and is driven by a 32 & 52x60" tandem compound engine. 



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STEEL 

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STEEL 

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STEEL 

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UNIVERSAL PLATE MILLS 

48" Universal Plate Mill rolls universal plates from slab ingots cast at Open Hearth Plants 
Nos. 1 and 2. It has six heating furnaces and is driven by a 50x60" reversing engine. 

42" Universal Plate Mill rolls universal plates from slabs furnished by the 30" Slabbing Mill. 
It is served by the same nine heating furnaces that serve the 128" Sheared Plate Mill and is driven 
by a 42x60" reversing engine. 



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STEEL 

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STEEL 

COMPANY 




48" Universal Plate Mill 



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Cooling Bed — 48" Universal Plate Mill 



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STEEL 

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STEEL 

COMPANY 






MERCHANT MILL 

This mill consists of three stands of 16", three stands of 12" and two stands of 9" rolls. It 
is served by three heating furnaces. The 16" and 12" stands are driven by a 32 & 52x60" tandem 
compound engine and the 9" stand by a 300 H. P. — A. C. motor. 



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ARMOR PLATE DEPARTMENT 

This department is an integral part of the Homestead Steel Works. It is here that all the 
armor plate made by the United States Steel Corporation is manufactured. 

To this department visitors are not admitted. 

The Vanadium Steel Department is included in the Armor Plate Department. 



HOMESTEAD 

STEEL 

WORKS 



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CARNEGIE 

STEEL 

COMPANY 



GENERAL EQUIPMENT 

This plant is well rounded out with all necessary supplementary departments such as machine 
shops, boiler shops, blacksmiths' shop, carpenter shop, electric repair shop, roll turning department, 
steel foundry, narrow gauge and standard gauge engine repair shops, chemical laboratories, physical 
testing laboratory, all kinds of storage sheds and bins, scrap yard and an emergency hospital. 



48 



AXLE DEPARTMENT 

The Howard Axle Works is a separate plant, built in Homestead, in 1899, but is under the 
direct management of Homestead Steel Works. This department employs about 600 men and 
consists of three heating furnaces, twelve 7,000 pound hammers and two 7,500 pound hammers, 
three straightening presses, lathes and all the other necessary equipment to make it a very complete 
and efficient axle plant. 

There is also a heat treating department at this plant, consisting of two furnaces with the 
necessary oil and water tanks for quenching. 



HOMESTEAD 

STEEL 

WORKS 



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CARNEOIE 

STEEL 

COMPANY 




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HOMESTEAD 

STEEL 

WORKS 



SLICK WHEEL DEPARTMENT 

This department has been developed and constructed during the last three years under the 
direction of Mr. E. E. Slick, Mechanical Engineer of the Carnegie Steel Company. 

The steel for this department is supplied in the form of ingots rolled into cylindrical blooms; 
sheared by a rotary shear into discs of various weights. 

These discs are then rolled and finished by the Slick or Schoen process into fly wheels, gear 
blanks, turbine discs, car wheels and other similar forms from 15" to 36" in diameter. 



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STEEL 

COMPANY 




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STEEL 

WORKS 




Slick Wheel Rolling Mill 



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CARNEOJE 

STEEL 

COMPANY 



SCHOEN STEEL WHEEL WORKS 

This plant is located at McKees Rocks, Pa., and was purchased by the Carnegie Steel Company 
in 1908. The plant is operated under the direct management of the Homestead Steel Works and 
employs about 600 men. 

This was the first plant ever built to manufacture rolled steel wheels. 

The steel for this plant comes from Homestead Steel Works in the form of discs, ready for 
forging and rolling, after having been rolled into cylindrical blooms and sheared by the Slick Rotary 
Shear to the desired weight. 

There are two Wheel Rolling Mills, and all the necessary equipment such as boilers, engines, 
forging presses, punches, lathes etc., to make it the equal of any steel wheel plant in the country. 



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STEEL 

WORKS 



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STEEL 

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HOMESTEAD 

STEEL 

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STEEL 

COMPANY 




Wheel Rolling Mill — Schoen Steel Wheel Works 






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STEEL 

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Property of 

Carnegie Steel Company 

HOMESTEAD STEEL WORKS 
HOMESTEAD PA 

JCrfLl: H»i»T r«ia» 1907 

orrtce or CH'Er cnoinccr, riTTSBURo P/». 



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General Plan of Works Showing Course for Visitors to Follow Through the Mill 



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